Fuel sender assembly

ABSTRACT

A fuel sender assembly having a housing, a first positioning mechanism, a second positioning mechanism and a sender unit. The first positioning mechanism contacts an outer surface of the housing and is movable in a first direction relative to the housing. The first positioning mechanism is further configured to retain the sender unit in any one of a plurality of positions relative to the outer surface of the housing. The second positioning mechanism includes a first part and a second part. The first part is attached to the first positioning mechanism. The second part is coupled to the first part such that the second part is movably positionable relative to the first part in a second direction perpendicular to the first direction. The sender unit is connected to the second part.

BACKGROUND Field of the Invention

The present invention generally relates to a fuel pump assembly that includes a sender unit. More specifically, the present invention relates to a fuel pump assembly that includes a sender unit that can be adjustably positioned to a plurality of locations and orientations relative to a fuel pump housing of the fuel pump assembly.

Background Information

A fuel tank within a vehicle includes a sender unit with a float. The float moves in response to changes in the amount of fuel within the fuel tank sending signals to a fuel gauge such that the fuel gauge displays an indication of the amount of fuel remaining in the fuel tank. In many vehicles, the sender unit is structurally assembled with a fuel pump assembly. Fuel tanks vary in size and shape depending upon the design of the vehicle, and the space within a vehicle body structure that can receive the fuel tank. Further fuel tanks often include a baffle or baffles within the fuel receiving interior of the fuel tank in order to restrict movement of fuel therein. Typically, each fuel tank must have a unique sender unit and fuel pump assembly designed to fit within the fuel tank and be shaped to avoid contact with any baffle or baffles therein. Consequently, there are countless numbers of sender unit and fuel pump assembly designs and configurations.

SUMMARY

An object of the current disclosure is to provide a fuel sender assembly with position adjusting mechanisms that permit a single fuel sender assembly to be easily re-oriented such that the fuel sender assembly and corresponding fuel pump assembly can be installed in any of a variety of differing fuel tank configurations and designs.

In view of the state of the known technology, one aspect of the present disclosure is to provide a fuel sender assembly with a housing, a first positioning mechanism, a second positioning mechanism and a sender unit. The housing is supported to the attachment section and has an outer surface. The first positioning mechanism has a housing engaging part and a retaining mechanism. The housing engaging part engages the outer surface of the housing and is movable in a first direction relative to the housing. The retaining mechanism is configured to retain the first positioning mechanism in any one of a plurality of positions relative to the outer surface of the housing. The second positioning mechanism includes a first part attached to the first positioning mechanism for movement therewith, a second part coupled to the first part and a locking mechanism operable between an unlocked state and a locked state such that in the unlocked state the second part is movable relative to the first part in a second direction perpendicular to the first direction and in the locked state the second part is non-movably fixed to the first part. The sender unit is connected to the second part of the second positioning mechanism, the sender unit including a float configured to move in an upward direction relative to the second part of the second positioning mechanism in response to changes in level of fuel.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of this original disclosure:

FIG. 1 is a perspective view of a vehicle that includes a fuel tank in accordance with a first embodiment;

FIG. 2 is a schematic top view of the vehicle depicted in FIG. 1 showing elements of the vehicle including an engine, fuel line, the fuel tank, and a fuel pump and sender unit assembly in accordance with the first embodiment;

FIG. 3 is a schematic side view showing the engine of the vehicle, a fuel vapor management system, the fuel tank and the fuel pump and sender unit assembly in accordance with the first embodiment;

FIG. 4 is a top view of a portion of the fuel tank, showing an attachment plate of the fuel pump and sender unit assembly in accordance with the first embodiment;

FIG. 5 is a side schematic view of the fuel pump and sender unit assembly removed from the vehicle showing a fuel pump housing in a first position relative to the attachment plate in accordance with the first embodiment;

FIG. 6 is another side schematic view of the fuel pump and sender unit assembly similar to FIG. 5 showing the fuel pump housing in a second position relative to the attachment plate in accordance with the first embodiment:

FIG. 7 is a side cross-sectional view of the fuel pump and sender unit assembly showing details of first and second telescoping sections configured to allow vertical positioning of the fuel pump housing relative to the attachment plate with the fuel pump housing in the second position (FIG. 6) in accordance with the first embodiment;

FIG. 8 is another side cross-sectional view of the fuel pump and sender unit assembly similar to FIG. 7 showing the details of first and second telescoping sections configured to allow vertical positioning of the fuel pump housing relative to the attachment plate with the fuel pump housing in the first position (FIG. 5) in accordance with the first embodiment;

FIG. 9 is a schematic side view of a first example of a fuel tank with the fuel pump and sender unit assembly installed therein in accordance with the first embodiment;

FIG. 10 is a schematic side view of a second example of a fuel tank with the fuel pump and sender unit assembly installed therein in accordance with the first embodiment;

FIG. 11 is a schematic side view of a third example of a fuel tank with the fuel pump and sender unit assembly installed therein in accordance with the first embodiment;

FIG. 12 is a schematic side view of the fuel pump and sender unit assembly similar to FIGS. 5 and 6 showing the sender unit in a first orientation relative to the fuel pump housing with a float of the sender unit in a fuel low position in accordance with the first embodiment;

FIG. 13 is another schematic side view of the fuel pump and sender unit assembly similar to FIG. 12 showing the float of the sender unit in a mid-position in accordance with the first embodiment;

FIG. 14 is another schematic side view of the fuel pump and sender unit assembly similar to FIGS. 12 and 13 showing the float of the sender unit in a fuel tank full position in accordance with the first embodiment;

FIG. 15 is another schematic side view of the fuel pump and sender unit assembly similar to FIGS. 12-14 showing the sender unit in a second orientation relative to the fuel pump housing, with the sender unit being rotated approximately 90 degrees from the first orientation via a first positioning mechanism, and with the sender unit in a lower most vertical position via function of a second positioning mechanism in accordance with the first embodiment;

FIG. 16 is another schematic side view of the fuel pump and sender unit assembly similar to FIGS. 12-15 showing the sender unit in the second orientation relative to the fuel pump housing, and with the sender unit in one of a plurality of intermediate vertical positions via function of the second positioning mechanism in accordance with the first embodiment;

FIG. 17 is another schematic side view of the fuel pump and sender unit assembly similar to FIGS. 12-16 showing the sender unit in the second orientation relative to the fuel pump housing, and with the sender unit in an uppermost vertical position via function of the second positioning mechanism in accordance with the first embodiment;

FIG. 18 is a side view of portions of the fuel pump and sender unit assembly showing details of the first positioning mechanism and the second positioning mechanism of the sender unit in accordance with the first embodiment;

FIG. 19 is a top cross-sectional view of the fuel pump and sender unit assembly showing further details of the first positioning mechanism and the second positioning mechanism of the sender unit in accordance with the first embodiment;

FIG. 20 is a cutaway view of a locking mechanism of the second positioning mechanism of the sender unit in accordance with the first embodiment;

FIG. 21 is a cutaway view of a first alternate locking mechanism of the second positioning mechanism of the sender unit in accordance with the first embodiment;

FIG. 22 is a cutaway view of a second alternate locking mechanism of the second positioning mechanism of the sender unit in accordance with the first embodiment;

FIG. 23 is a schematic view of the sender unit and associated circuitry connecting the sender unit to a linear resistance panel and a resistance setting switch thereof to a controller and instrument panel display in accordance with the first embodiment;

FIG. 24 is a cross-sectional view of a portion of the fuel pump and sender unit assembly showing a vapor valve section thereof with portions of the fuel pump and sender unit removed for clarity and simplicity, further showing a first valve assembly in a first vertical position and a second valve assembly in a first vertical position in accordance with the first embodiment;

FIG. 25 is another cross-sectional view of the portion of the fuel pump and sender unit assembly depicted in FIG. 24 showing the first valve assembly moved to a second vertical position and the second valve assembly moved to a second vertical position in accordance with the first embodiment;

FIG. 26 is a cross-sectional view of a portion of the first valve assembly showing details of a recess and projection arrangement that is used to lock the first valve assembly in any one of a plurality of vertical positions including the first and second vertical positions depicted in FIGS. 24 and 25, in accordance with a first embodiment;

FIG. 27 is a cut-away view of the portion of the first valve assembly showing details of the recess and projection arrangement that is used to lock the first valve assembly in any one of the plurality of vertical positions including the first and second vertical positions depicted in FIGS. 24 and 25, in accordance with the first embodiment;

FIG. 28 is another cross-sectional view of a portion of the first valve assembly showing details of an alternative configuration of a recess and projection arrangement used to lock the first valve assembly in any one of a plurality of vertical positions, in accordance with the first embodiment;

FIG. 29 is a cutaway view of a portion of the first valve assembly showing a locking mechanism in accordance with a second embodiment; and

FIG. 30 is a cross-sectional view of the portion of the first valve assembly depicted in FIG. 29 showing further details of the locking mechanism in accordance with the second embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Referring initially to FIG. 1, a vehicle 10 is illustrated in accordance with a first embodiment. As shown schematically in FIG. 2, the vehicle 10 includes a fuel tank 12 and a fuel pump assembly 14 (also referred to as a fuel pump and sender unit assembly). The fuel pump assembly 14 is configured such that portions thereof can undergo positioning adjustments in order to install the fuel pump assembly 14 is a variety of differing fuel tank shapes and configurations, as is described in greater detail below.

The vehicle 10 is depicted as a four door sedan. However, it should be understood from the drawings and the description below that the vehicle 10 can be any of a variety of vehicle designs, such as a pickup truck, a commercial van, a passenger van, coupe or SUV (sports utility vehicle). In particular, as described below, the fuel tank 12 of the vehicle 10 can have any of a variety of shapes and configurations.

The vehicle 10 includes, among other components, a vehicle body structure 18, an engine 20, a transmission 22, a controller 24, an instrument panel display 26, a fuel filler structure 28, a fuel vapor management system 30, the fuel tank 12 and the fuel pump assembly 14.

The vehicle body structure 18 includes an engine compartment 18 a, a passenger compartment 18 b and a cargo area 18 c. The internal combustion engine 20 can be a gasoline powered engine, a diesel engine or a hybrid engine with both a hydrocarbon fuel power section and an electric power section. The transmission 22 can be an automatic transmission or a manual transmission.

The controller 24 can be, for example, an onboard computer that controls functions and operations of, for example, ignition, fuel consumption and emissions the engine 20, shifting of the transmission 22, operation of an air conditioning system (not show) and/or other vehicle components as needed or desired. The controller 24 can also be connected to the instrument panel display 26 and the fuel pump assembly 14 in order to display a current level of fuel in the fuel tank 12, as described in greater detail below.

The fuel filler structure 28 is a conventional structure that is positioned along an exterior surface of the vehicle body structure 18 and includes a filler tube 32 that extends to the fuel tank 12 in a conventional manner in order to direct fuel from outside the vehicle 10 to the fuel tank 12.

As shown in FIG. 3, the fuel vapor management system 30 is part of an overall emission control system of the vehicle 10. Since emission control systems and fuel vapor management systems are conventional features of vehicles, such as the vehicle 10, further description is omitted for the sake of brevity. Only those features necessary for understanding the fuel pump assembly 14 are described herein below.

The fuel tank 12 is shown schematically in FIG. 2. The fuel tank 12 is dimensioned and shaped to retain fuel (not shown) for the use by the engine 20. The fuel tank 12 is a sealed vessel that includes an opening 36 defined along an upper wall thereof. As shown in FIG. 4, the fuel tank 12 includes a flange 38 that surrounds the opening 36. The opening 36 is configured to receive and attach to the fuel pump assembly 14 in a conventional manner. Once the fuel pump assembly 14 is installed to the opening 36, the fuel tank 12 is sealed in a conventional manner. The fuel tank 12 can have many different shapes and configurations, as is described further below after a description of portions of the fuel pump assembly 14.

As shown in FIGS. 4-8, when removed from the fuel tank 12, the fuel pump assembly 14 basically includes an attachment section 40, a pump section 42, a sender unit section 44 and a vapor valve section 46.

As shown in FIG. 4, the attachment section 40 of the fuel pump assembly 14 includes a disk shaped plate 50 that is configured to fixedly attach the fuel pump assembly 14 to the fuel tank 12, with the pump section 42 extending downward into the fuel tank 12. An outer periphery of the plate 50 defines an attachment flange for attaching to the fuel tank 12. The plate 50 can optionally include one or more alignment projections 50 a. The plate 50 further has an exterior side 50 b and an interior side 50 c. The plate 50 also includes a first tube 52, a second tube 54, a fuel tube 56 a connector 58 and the vapor valve section 46 (as described further below). The first tube 52 and the second tube 54 extend through the plate 50 from the exterior side 50 b to the interior side 50 c. The first tube 52 and the second tube 54 are dimensioned and arranged to allow movement of fuel vapors in and/or out of the fuel tank 12 through the vapor valve section 46, as is described further below.

The fuel tube 56 also extends through the plate 50 from the exterior side 50 b to the interior side 50 c. A first end of the fuel tube 56 is connected via a fuel line 60 to the engine 20, as shown in FIG. 3, and a second end connected to a flexible line 62 which is in turn connected to the pump section 42 as shown in FIGS. 5 and 6, and described in greater detail below. The connector 58 is configured to attach to a connector (not shown) of a wiring harness 64 that includes various electrical wires thereby electrically connecting the controller 24 with the fuel pump assembly 14. More specifically, the wiring harness 64 includes wires that connect the sender unit section 44 with the controller 24 in order to provide fuel level indicating signals from the sender unit section 44, and include wires that connect the controller 24 to the pump section 42, selectively providing power to the pump section 42 thereby powering a fuel pump 76 of the pump section 42.

A description of the pump section 42 is now provided with specific reference to FIGS. 5-8. The pump section 42 includes a housing 70, a first telescoping section 72, a second telescoping section 74 and the fuel pump 76. The fuel pump 76 is located within the interior of the housing 70 and is configured to draw fuel out of the fuel tank 12 and deliver it to the engine 20 in a conventional manner. The fuel pump 76 can be any of a variety of designs, such as an impeller type pump, a piston type pump or other pump configuration that can pump liquid from one location to another locations. Since fuel pumps are convention vehicle components, further description is omitted for the sake of brevity.

The housing 70 includes a fuel pump outlet 76 a connected to the flexible line 62 such that fuel pumped from fuel pump 76 within the housing 70 moves through the flexible line 62, through the fuel tube 56, further through the fuel line 60 and to the engine 20. The sender unit section 44 is adjustably installed to an outer surface of the housing 70 in a manner described in greater detail below.

The housing 70 also includes a pair of support bores 78. The housing 70 is supported to the plate 50 of the attachment section 40 via the first telescoping section 72 and the second telescoping section 74, as shown in FIGS. 5-8. The first telescoping section 72 and the second telescoping section 74 are basically identical structures, each having an upper telescoping section 80, a support rod 82, a first spring 84 and a second spring 86. Therefore, description of one of the first telescoping section 72 and the second telescoping section 74 applies equally to the other.

The upper telescoping sections 80 are rigidly fixed to the plate 50 by, for example, welding techniques or mechanical fasteners (not shown). The upper telescoping sections 80 basically define outer portions of respective telescoping structures. Specifically, upper ends of the support rods 82 extend into bores 80 a of the upper telescoping section 80 such that the support rods 82 are vertically moveable relative to the upper telescoping sections 80, as demonstrated by the relative movement depicted in FIGS. 7 and 8. The first springs 84 are disposed within respective ones of the bores 80 a. The first springs 84 are located above respective ones of the support rods 82 such that each of the first springs 84 is confined between the interior side 50 c (a lower surface) of the plate 50 within the bore 80 a and a top surface of the support rod 82. Hence, the support rods 82 are biased for downward telescoping movement relative to the upper telescoping sections 80. In other words, the first springs 84 (biasing members) urge the support rods 82 away from the attachment section 40.

The upper telescoping sections 80 (the outer portion) of the telescoping structures 72 and 74 each include an aperture 80 b that extends in a direction perpendicular to and through the bore 80 a. The aperture 80 b is dimensioned to receive an optional locking pin P₁ insertable into the aperture 80 b such that with the locking pin P₁ inserted into the aperture 80 b the locking pin P₁ limits overall movement of the support rod 82 relative to upper telescoping section 80 (the outer portion) as indicated in FIG. 7.

A lower portion 82 a of each of the support rods 82 extends into a corresponding one of the support bores 78 of the housing 70 such that the support rods 82 can undergo telescoping movement with respect to the housing 70. The second springs 86 are disposed about each of the support rods 82 and are confined between the upper telescoping section 72 and the housing 70. Consequently, the housing 70 is biased by the second springs 86 to move downward away from the attachment section 40.

The fuel pump assembly 14 is installed to the fuel tank 12 such that the pump section 42 is inserted through the opening 36 into the fuel tank 12 until the plate 50 contacts the flange 38. A locking ring (not shown) attaches to the flange 38 in a conventional manner, fixing the plate 50 and the fuel pump assembly 14 to the fuel tank 12. During installation of the fuel pump assembly 14, a lower surface 70 a (FIGS. 5 and 6) of the housing 70 contacts and can be pressed against a bottom interior surface 12 a of the fuel tank 12 (FIG. 9). Depending upon the overall height of the fuel pump assembly 14 and the overall depth of the fuel tank 12, it is possible for the first and second telescoping section 72 and 74 to undergo compressive telescoping movement (the first and second springs 84 and 86 can be compressed) thereby changing an overall height of the fuel pump assembly 14.

As described above, the first and second telescoping sections 72 and 74 allow for movement of the housing 70 of the pump section 42 relative to the attachment section 40 and the plate 50. In other words, the fuel pump assembly 14 is a multi-application assembly that can be used in a variety of fuel tank configurations. For example, FIGS. 9, 10 and 11 show several possible configurations of fuel tanks. The fuel pump assembly 14 is configured to be installed in any of a plurality of fuel tank designs. FIGS. 9, 10 and 11 show only three possible fuel tank designs. It should be understood from the drawings and description herein, that the fuel pump assembly 14 can be used in many different fuel tank designs and configurations.

For example, in FIG. 9, the fuel tank 12 has an overall depth D₁ that is such that when the fuel pump assembly 14 is installed therein, the fuel pump assembly 14 has an overall height H₁. In FIG. 6, the fuel pump assembly 14 is shown with the first and second telescoping sections 72 and 74 fully extended. In other words, both FIGS. 6 and 9 show the fuel pump assembly 14 at the overall height H₁ representing a maximum height thereof. In FIG. 10, the fuel pump assembly 14 is installed to an alternative fuel tank 12′. The fuel tank 12′ has an overall depth D₂ that is less than the overall depth D₁ of the fuel tank 12. Consequently, when the fuel pump assembly 14 is installed to the fuel tank 12′, the fuel pump assembly 14 has an overall height H₂ that is less than the overall height H₁. The first and second telescoping sections 72 and 74 are compressed in the installation orientation shown in FIG. 10.

In FIG. 11, the fuel pump assembly 14 is installed to yet another alternative fuel tank 12″. The fuel tank 12″ has an overall depth D₃ that is less than the overall depth D₁ and the overall depth D₂. Consequently, when the fuel pump assembly 14 is installed to the fuel tank 12″, the fuel pump assembly 14 has an overall height H₃ that is less than the overall height H₁ and the overall height H₂. The first and second telescoping sections 72 and 74 are fully compressed in the configuration shown in FIG. 11. Similarly, FIG. 5 also shows the fuel pump assembly 14 with the overall height H₃ that represents a minimum height thereof.

It should be understood from the drawings and the description herein that the fuel pump assembly 14 can be installed in a significant number of fuel tank configurations and is not limited to the three examples of fuel tanks depicted in FIG. 9-11. More specifically, since the first and second telescoping sections 72 and 74 allow the pump section 42 of the fuel pump assembly 14 to move relative to the attachment section 40, the fuel pump assembly 14 can have any of dozens of overall heights ranging between the overall height H₃ and the overall height H₁.

A description of the sender unit section 44 is now provided with specific reference to FIGS. 12-22. The sender unit section 44 is attached to the housing 70 of the pump section 42 of the fuel pump assembly 14. Specifically, the sender unit section 44 is connected to the housing 70 such that a sender unit 90 having a float 92 can be adjustably positioned in a plurality of orientations relative to the housing 70, and the plate 50 of the attachment section 40. More specifically, the entire sending unit 90 can be positioned at any of a plurality of circumferentially spaced apart locations about the housing 70 (a first direction—a horizontally oriented direction). Further, the sending unit 90 can be moved and positioned vertically (a second direction perpendicular to the first direction) to any of a plurality of locations relative to the housing 70.

The sender unit section 44 includes a first positioning mechanism 94, a second positioning mechanism 96 and the sender unit 90. The first positioning mechanism 94 is supported on the housing 70. The housing 70 has an outer surface 70 b that is cylindrical in shape, or has a portion thereof that has an annular cylindrical shape. The first positioning mechanism 94 has a housing engaging part 100 and a retaining mechanism 102. The housing engaging part 100 has an annular shape and extends completely around the outer surface 70 b of the housing 70. The housing engaging part 100 can be made of two half annular elements that are fastened together via mechanical fasteners (not shown) to form the complete annular ring that defines the housing engaging part 100. The housing engaging part 100 is rotatably movable in the first direction relative to the housing 70. Specifically, the first direction is a horizontal and circular direction relative to the housing 70. As shown schematically in FIGS. 12-14, the housing engaging part 100 is shown in a first position relative to the housing 70. As shown schematically in FIGS. 15-17, the housing engaging part 100 is rotated to a second position relative to the housing 70 that is approximately 90 degrees offset from the first position.

From the side view in FIGS. 12-17, it is shown that the housing engaging part 100 remains along a horizontally extending plane P₂ (FIG. 12) defined on the housing 70. In other words, the housing engaging part 100 does not move in a vertical direction, but remains in positions that intersect with the horizontal plane P₂. As shown in FIG. 18, the housing engaging part 100 can be retained in positions intersecting with the horizontal plane P₂ by, for example, rings 100 a mounted to the housing 70 above and below the housing engaging part 100, thereby restricting vertical movement. The rings 100 a can be attached to the housing 70 by fasteners (not shown), can be force fitted to the housing 70 or can be integrally molded with the housing 70.

The rotary movement of the housing engaging part 100 about the housing 70 is restricted by the retaining mechanism 102 shown in FIG. 19. The retaining mechanism 102 is configured to retain the first positioning mechanism 100 in any one of a plurality of positions relative to the outer surface of the housing. One example of the retaining mechanism 102 shown in FIG. 19 is such that the outer surface 70 b is provided with or formed with a plurality of gear teeth or recesses 102 a and the housing engaging part 100 include a spring biased ball detent 102 b (a resilient projection). The ball detent 102 b is continuously urged into contact with the recesses 102 a restricting movement of the housing engaging part 100 relative to the housing 70. A predetermined amount of force applied to the housing engaging part 100 overcomes the biasing forces acting on the ball detent 102 b allowing positioning of the housing engaging part 100 relative to the housing 70. Hence, the housing engaging part 100 can be rotated about the housing 70 to any of a plurality of positions, limited only by the number and circumferential positioning of the recesses 102 a.

It should be understood from the drawings and the description herein that the relative locations of the recesses 102 a and the ball detent 102 b can be switched. Specifically, the recesses 102 a can be formed on the housing engaging part 100 and the ball detent 102 b can be located on the housing 70. More specifically, one of the outer surface 70 b of the housing 70 and the housing engaging part 100 includes the ball detent 102 b (the resilient projection) and the other of the outer surface 70 b of the housing 70 and the housing engaging part 100 includes the plurality of recesses 102 a. Hence, in response to rotation of the housing engaging part 100 about the outer surface 70 b of the housing 70 the ball detent 102 b (the resilient projection) is moved relative to the plurality of recesses 102 a from engagement with one of the plurality of recess 102 a to engagement with another of the plurality of recesses 102 a.

It should also be understood from the drawings and the description that alternative mechanisms for restricting movement of the housing engaging part 100 relative to the housing 70 can be employed, such as a clamping mechanism, or a locking mechanism. The first positioning mechanism 94 is only operated upon installation of the fuel pump assembly 14 to the fuel tank 12. In other words, the first positioning mechanism 94 need not be overly complex and is only intended to be operated once to position the sender unit 90 relative to the housing 70 as the fuel pump assembly 14 is installed into the fuel tank 12. As noted above, the fuel tank 12 can have any of a variety of shapes and configurations, and may include baffles (not shown) within its interior fuel carrying space. For some fuel tank installation applications, it can be necessary to re-position the sender unit 90 to a predetermined location in order to avoid a baffle, or avoid an irregularity in the bottom surface of the fuel tank 12.

As shown in FIGS. 18 and 19, the second positioning mechanism 96 includes a first part 106, a second part 108 and a locking mechanism 110 (FIGS. 20-22). The first part 106 is fixedly attached to the housing engaging part 100 of the first positioning mechanism 94 for movement with the housing engaging part 100. The second part 108 is coupled to the first part 106 such that the second part 108 can undergo linear movement in a vertical direction relative to the housing 70. Specifically, as shown in FIGS. 15, 16 and 17, the second part 108 (along with the sender unit 90) can be moved in vertical directions to a plurality of positions relative to the housing engaging part 100 and the housing 70. FIG. 15 shows the second part 108 and the sender unit 90 in a lower-most position. FIG. 16 shows the second part 108 and the sender unit 90 in one of a plurality of intermediate positions. FIG. 17 shows the second part 108 and the sender unit 90 in an upper-most position.

Movement of the second part 108 relative to the first part 106 is vertical movement, whereas the movement of the housing engaging part 100 relative to the housing 70 is horizontal/circular movement. Hence, the second positioning mechanism 96 allows for positioning of the sender unit 90 in a direction that is perpendicular to the positioning of the sender unit 90 provided by the first positioning mechanism 94.

The locking mechanism 110 shown in FIG. 20 is operable between an unlocked state and a locked state. In the unlocked state the second part 108 is movable relative to the first part 106 in vertical directions (up and down in the second direction) perpendicular to horizontal movement of the housing engaging part 100 (the first direction). In the locked state the second part 108 is non-movably fixed to the first part 106. The locking mechanism 110 can be any of a variety of mechanisms. For example, as shown in FIG. 20, the locking mechanism 110 can be a flexible locking tab 110 a formed on a portion of the second part 108 that is insertable into any one of a plurality of recesses 110 b formed along one edge of the first part 106. The flexible locking tab 110 a is pulled back to the unlocked state (in phantom in FIG. 20) unlocking the second part 108 from the first part 106 allowing vertical movement and positioning of the sender unit 90. The flexible locking tab 110 a resiliently moves into the adjacent one of the plurality of recesses 110 b locking the second part 108 into position relative to the first part 106 (the locking state).

FIGS. 21 and 22 show alternatives to the locking mechanism 110. Specifically, in FIG. 21, a locking mechanism 110′ includes biasing members 112 that urge the first part 106 and the second part 108 toward one another. In the alternative locking mechanism 110′ in FIG. 21, the first part 106 includes a plurality of gear teeth or recesses 106 a and the second part 108 includes at least one gear tooth or projection 108 a that engages the recesses 106 a. Force applied to the second part 108 moves the projection 108 a out of the recesses 106 a allowing movement of the second part 108 relative to the first part 106, thereby allowing the second part 108 and the sender unit 90 to be positioned vertically relative to the first part 106 and the housing 70. Similarly, in the alternative locking mechanism 110″ in FIG. 22, the first part 106 includes a plurality of recesses 106 b and the second part 108 includes at least one projection 108 b that engages the recesses 106 b. Force applied to the second part 108 moves the projection 108 b out of the recesses 106 b allowing movement of the second part 108 relative to the first part 106, thereby allowing the second part 108 and the sender unit 90 to be positioned vertically relative to the first part 106 and the housing 70.

As shown in FIGS. 18 and 19, the sender unit 90 is fixedly attached to the second part 108 of the second positioning mechanism 96, such that the sender unit 90 moves with the second part 108 during positioning of the second part 108 relative to the first part 106. The sender unit 90 includes the float 92, a linear resistance panel 114 and a resistance setting switch 116. The sender unit 90 has a recessed area 90 a. The float 91 is supported by a slider 118 that is retained within the recessed area 90 a for linear sliding movement in vertical directions (up and down). The slider 118 is a first track part that is T-shaped projection as viewed in cross-section in FIG. 19. The recessed area 90 a is basically a second track part that includes two opposing recesses dimensioned to receive and mate with the T-shaped projection of the slider 118. The slider 118 along with the float 92 can undergo linear vertical movement along the recessed area 90 a (a slider track). Hence the slider 118 and the float 92 are movable between a plurality of positions along recessed area 90 a (the slider track) as shown in FIGS. 12, 13 and 14. Specifically, FIGS. 12, 13 and 14 show the float 92 moved between various vertical positions along the recessed area 90 a. The float 92 is configured to float along the surface of fuel in the fuel tank 12, thereby providing an indication of the amount of fuel in the fuel tank 12. The float 92 and the slider 118 are configured to move in an upward direction relative to the second part 108 of the second positioning mechanism 96 in response to changes in level of fuel.

The linear resistance panel 114 is a resistance measuring part that provides an electronic indication of electrical resistance at each of the plurality of positions of the float 92. The linear resistance panel 114 is located within the recessed area 90 a of the sender unit 90. The slider 118 contacts the linear resistance panel 114 (a slider track) in a conventional manner completing a circuit that provides the controller 24 with differing resistance signals indicating fuel level. As described above, the fuel pump assembly 14 is designed for use in a plurality of differing fuel tank designs and also in a plurality of differing vehicle designs. Some vehicles determine fuel levels in its fuel tank based on one range of measured resistances and other vehicle can have a different range of resistances. As shown in FIG. 23, the resistance setting switch 116 is part of a circuit and includes is a multi-position switch such that in a first position S₁, the linear resistance panel 114 and the positioning of the slider 118 output resistances within a first range, with one end of the range being zero ohms, and a second end being a first predetermined ohm reading. In a second position S₂, the linear resistance panel 114 and the positioning of the slider 118 output resistances within a second range, with one end of the range being zero ohms, and a second end being a second predetermined ohm reading greater than the first predetermined ohm reading. Further, in a third position S₃, the linear resistance panel 114 and the positioning of the slider 118 outputs resistances within a third range, with one end of the range being zero ohms, and a third end being a third predetermined ohm reading that differs from both the first and second predetermined ohm readings.

A description is now provided for the vapor valve section 46 with specific reference to FIGS. 24-28. The vapor valve section 46 is part of the fuel vapor management system 30 shown in FIG. 3. The fuel vapor management system 30 captures hydrocarbon vapors from fuel and from the inlet of the filler tube 32 in a conventional manner. The fuel vapor management system 30 shown in FIG. 3 is a schematic rendering of a convention vapor management system. Since fuel vapor management systems are well known, further description is omitted for the sake of brevity.

The vapor valve section 46 is attached to the interior side 50 c (or underside) of the plate 50 of the attachment section 40. In FIGS. 24 and 25, various features of the plate 50, such as the fuel tube 56 and the connector 58 are omitted for the sake of clarity and simplicity.

The vapor valve section 46 basically includes a first valve assembly 120 (a first air flow valve assembly) and a second valve assembly 122 (a second air flow valve assembly). The first valve assembly 120 supported below the plate 50 and is aligned with a vapor passageway of the first tube 52. The first tube 52 basically extends through the plate 50 of the attachment section 40 as shown in FIGS. 24 and 25.

The first valve assembly 120 includes a first tube 130, a second tube 132 (a first housing portion), a housing 134 (a second housing portion), a valve seat portion 136 and a float 138. The first tube 130 is rigidly fixed to the interior side 50 c of the plate 50. The first tube 130 is hollow and is aligned with the vapor passageway of the first tube 52. The second tube 132 is also rigidly fixed to the interior side 50 c of the plate 50 such that the second tube 132 is concentric with the first tube 130 and surrounds the first tube 130. A hollow annular channel 132 a is defined between at least a portion of the first tube 130 and the second tube 132.

The housing 134 has a lower portion that defines a float chamber 134 a. An upper portion of the housing 134 defines an annular attachment flange 134 b that contacts and slides along an outer surface of the second tube 132, such that the annular attachment flange creates a seal between the housing 134 and the second tube 132. Hence, the housing 134 is slidably supported on the second tube 132, as demonstrated by a comparison of the depictions in FIGS. 24 and 25. Specifically, the housing 134 can slide up and down along the second tube 132 in order to accommodate installation into any of a variety of fuel tanks and fuel tank configurations.

In the depicted embodiment, the second tube 132 includes a pair of projections 132 b and the housing 134 defines a pair of recesses along an interior surface thereof, the recesses each having that a vertical portion R_(V) and a plurality of horizontal recess portions R_(H) that extend to the vertical portion R_(V). The projections 132 b of the second tube 132 extend the recess and can be moved along the vertical portion R_(V) or into any one of the plurality of horizontal recess portions R_(H)w. The projections 132 b, the horizontal recess portions R_(H) and the vertical portion R_(V) are also shown in FIGS. 26 and 27.

In order to re-position the housing 134 relative to the second tube 132, the housing 134 can be rotated relative to the second tube 132 in order to align the projections 132 b with the vertical portion R_(V). The housing 134 can then be repositioned vertically relative to the second tube 132 with the projections 132 b remaining in the vertical portion R_(V) of the recess. In order to lock the housing 134 in one of a plurality of vertical positions relative to the second tube 132, the housing 134 is rotated in order to move the projections 132 b into ones of the plurality of horizontal recess portions R_(H). The vertical portion R_(V), the plurality of horizontal recess portions R_(H) and the projections 132 b (parts of the first housing portion and the second housing portion) define a position locking mechanism that retains the housing 134 (the second housing portion) in one of a plurality of positions relative to the second tube 132 (the first housing portion).

As shown in FIG. 28, it is also possible to reverse the locations of the projections and recesses of the first valve assembly 120. Specifically, the housing 134 and second tube 132 can be modified or replaced with a housing 134′ and a second tube 132′. The housing 134′ is provided with projections 134 e′ that extend into the recesses R_(V) and R_(H) formed in the second tube 132′.

The valve seat portion 136 is rigidly attached to an interior portion of the housing 134 for movement with the housing 134. The valve seat portion 136 includes a sleeve part 136 a, an engagement part 136 b and a seat part 136 c. The sleeve part 136 a is dimensioned to fit around an outer periphery of the first tube 130 and slide within the hollow annular channel 132 a. More specifically, the sleeve part 136 a can undergo telescoping movement relative to the first tube 130. The engagement part 136 b of the valve seat portion 136 extends into the float chamber 134 a and defines the sear part 136 c. The engagement part 136 b is coupled to the housing 134 for movement therewith. The valve seat portion 136 defines a central bore 136 d open to the vapor passageway of the first tube 56 and is open to the seat part 136 c.

The float 138 is disposed within the float chamber 134 a and is freely movable within the float chamber 134 a. Consequently, in response to fluid entering the float chamber 134 a via openings 134 c, the float 138 floats up against the seat part 136 c closing off the central bore 136 d and the vapor passageway of the first tube 52. In the absence of fluid, the float 138 moves downward in the float chamber 134 a exposing the seat part 136 c and the central bore 136 d allowing vapor movement through the vapor passageway of the first tube 52.

The second valve assembly 122 is similar to the first valve assembly 120 in configuration and operation. Specifically the second valve assembly 122 includes a third tube 140, a fourth tube 142 (a third housing portion), a housing 144 (a fourth housing portion), a valve seat portion 146 and a float 148. The third tube 140 is rigidly fixed to the interior side 50 c of the plate 50. The third tube 140 is hollow and is aligned with the vapor passageway of the second tube 54. The fourth tube 142 is also rigidly fixed to the interior side 50 c of the plate 50 such that the fourth tube 142 is concentric with the third tube 140 and surrounds the third tube 140. A hollow annular channel 142 a is defined between at least a portion of the third tube 140 and the fourth tube 142.

The housing 144 has a lower portion that defines a float chamber 144 a. An upper portion of the housing 144 defines an annular attachment flange 144 b that contacts and slides along an outer surface of the fourth tube 142, such that the annular attachment flange creates a seal between the housing 144 and the fourth tube 142. Hence, the housing 144 is slidably supported on the fourth tube 142, as demonstrated by a comparison of the depictions in FIGS. 24 and 25. Specifically, the housing 144 can slide up and down along the fourth tube 142 in order to accommodate installation into any of a variety of fuel tanks and fuel tank configurations.

In the depicted embodiment, the fourth tube 142 includes a pair of projections 142 b and the housing 144 defines a pair of recesses along an interior surface thereof, the recesses each having that a vertical portion R_(V) and a plurality of horizontal recess portions R_(H) that extend to the vertical portion R_(V) similar to the recess in the housing 132. The projections 142 b of the fourth tube 142 extend the recess and can be moved along the vertical portion R_(V) or into any one of the plurality of horizontal recess portions R_(H).

In order to re-position the housing 144 relative to the fourth tube 142, the housing 144 can be rotated relative to the fourth tube 142 in order to align the projections 142 b with the vertical portion R_(V). The housing 144 can then be repositioned vertically relative to the fourth tube 142 with the projections 142 b remaining in the vertical portion R_(V) of the recess. In order to lock the housing 144 in one of a plurality of vertical positions relative to the fourth tube 142, the housing 144 is rotated in order to move the projections 142 b into ones of the plurality of horizontal recess portions R_(H). The vertical portion R_(V), the plurality of horizontal recess portions R_(H) and the projections 142 b (parts of the third housing portion and the fourth housing portion) define a position locking mechanism that retains the housing 144 (the fourth housing portion) in one of a plurality of positions relative to the fourth tube 142 (the third housing portion). Since the vertical portion R_(V) and the plurality of horizontal recess portions R_(H) are generally the same as those in the first valve assembly 120, the depictions in FIGS. 26 and 27 also apply to the recess in the second valve assembly 122. Therefore, for the sake of brevity, a depiction of the recess in the second valve assembly 122 is omitted.

The valve seat portion 146 is rigidly attached to an interior portion of the housing 144 for movement with the housing 144. The valve seat portion 146 includes a sleeve part 146 a, an engagement part 146 b and a seat part 146 c. The sleeve part 146 a is dimensioned to fit around an outer periphery of the third tube 140 and slide within the hollow annular channel 142 a. More specifically, the sleeve part 146 a can undergo telescoping movement relative to the third tube 140. The engagement part 146 b of the valve seat portion 146 extends into the float chamber 144 a and defines the seat part 146 c. The engagement part 146 b is coupled to the housing 144 for movement therewith. The valve seat portion 146 defines a central bore 146 d open to the vapor passageway of the first tube 56 and is open to the seat part 146 c.

The float 148 is disposed within the float chamber 144 a and is freely movable within the float chamber 144 a. Consequently, in response to fluid entering the float chamber 144 a via openings 144 c, the float 148 floats up against the seat part 146 c closing off the central bore 146 d and the vapor passageway of the second tube 54. In the absence of fluid, the float 148 moves downward in the float chamber 144 a exposing the seat part 146 c and the central bore 146 d allowing vapor movement through the vapor passageway of the second tube 54.

The vertical positioning adjustment of each of the first valve assembly 120 and the second valve assembly 122 are provided to give further flexible installation features to the fuel pump assembly 14.

When the fuel tank 12 is full of fuel, at least the first valve assembly 120 is closed since the float 138 moves up into contact with the seat part 136 c of the valve seat portion 136. In this case, the second valve assembly 122 allows vapor to escape the fuel tank 12 when the fuel tank 12 is full and the first valve assembly 120 is closed.

In the event that the vehicle 10 rolls over, the float 138 contacts and seals with the seat part 136 c of the valve seat portion 136 and the float 148 contacts and seals with the seat part 146 c of the valve seat portion 146 thereby preventing fuel from escaping the fuel tank 12.

It should be understood from the drawings and the description herein that the first valve assembly 120 and the second valve assembly 122 can be connected to differing vapor lines of the fuel vapor management system 30 or the same vapor line of the fuel vapor management system 30, as needed or designed.

Second Embodiment

Referring now to FIGS. 29 and 30, a second tube 132″ and a housing 134″ in accordance with a second embodiment will now be explained. In view of the similarity between the first and second embodiments, the parts of the second embodiment that are identical to the parts of the first embodiment will be given the same reference numerals as the parts of the first embodiment. Moreover, the descriptions of the parts of the second embodiment that are identical to the parts of the first embodiment may be omitted for the sake of brevity. The parts of the second embodiment that differ from the parts of the first embodiment will be indicated with a double prime (″).

The first and second valve assemblies 120 and 122 described in the first embodiment can be modified to include a different position locking arrangement. Specifically, the second tube 132 and the housing 134 of the first embodiment can be replaced with the second tube 132 the housing 134″ and the housing 134″ of the second embodiment. The housing 134″ is provided with a series of recesses 134″_(R) and the second tube 132″ is provided with projections 132″_(B).

The controller 24 preferably includes a microcomputer with a fuel pump assembly control program that controls the fuel pump 76 and processes signals from the sender unit 90. The controller 24 can also include other conventional components such as an input interface circuit, an output interface circuit, and storage devices such as a ROM (Read Only Memory) device and a RAM (Random Access Memory) device. It will be apparent to those skilled in the art from this disclosure that the precise structure and algorithms for the controller 24 can be any combination of hardware and software that will carry out the functions of the present invention.

The various vehicle elements not described herein are conventional components that are well known in the art. Since these elements are well known in the art, these structures will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

General Interpretation of Terms

In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiments, the following directional terms “forward”, “rearward”, “above”, “downward”, “vertical”, “horizontal”. “below” and “transverse” as well as any other similar directional terms refer to those directions of a vehicle equipped with the fuel pump assembly. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a vehicle equipped with the fuel pump assembly.

The term “detect” as used herein to describe an operation or function carried out by a component, a section, a device or the like includes a component, a section, a device or the like that does not require physical detection, but rather includes determining, measuring, modeling, predicting or computing or the like to carry out the operation or function.

The term “configured” as used herein to describe a component, section or part of a device includes hardware and/or software that is constructed and/or programmed to carry out the desired function.

The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.

While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such features. Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. 

What is claimed is:
 1. A fuel sender assembly, comprising: a housing having an outer surface; a first positioning mechanism having a housing engaging part and a retaining mechanism, the housing engaging part engaging the outer surface of the housing and being movable in a first direction relative to the housing, the retaining mechanism being configured to retain the first positioning mechanism in any one of a plurality of positions relative to the outer surface of the housing; a second positioning mechanism including a first part attached to the first positioning mechanism for movement therewith, a second part coupled to the first part and a locking mechanism operable between an unlocked state and a locked state such that in the unlocked state the second part is movable relative to the first part in a second direction perpendicular to the first direction and in the locked state the second part is non-movably fixed to the first part; and a sender unit connected to the second part of the second positioning mechanism, the sender unit including a float configured to move in an upward direction relative to the second part of the second positioning mechanism in response to changes in level of fuel.
 2. The fuel sender assembly according to claim 1, wherein the housing includes a fuel pump mechanism disposed therein.
 3. The fuel sender assembly according to claim 1, further comprising a fuel tank having an opening formed in an upper wall thereof, and an annular support flange surrounding the circular opening, and an attachment section that includes a disk shaped flange dimensioned to mate with the annular support flange with the housing extending below the attachment section and into the fuel tank.
 4. The fuel sender assembly according to claim 1, wherein the outer surface of the housing has an overall cylindrical shape.
 5. The fuel sender assembly according to claim 4, wherein the housing engaging part has an annular shape and extends completely around the outer surface of the housing.
 6. The fuel sender assembly according to claim 5, wherein one of the outer surface of the housing and the retaining mechanism of the first positioning mechanism includes a resilient projection and the other of the outer surface of the housing and the retaining mechanism of the first positioning mechanism includes a plurality of recesses such that in response to rotation of the housing engaging part about the outer surface of the housing the resilient projection is moved relative to the plurality of recesses from engagement with one of the plurality of recess to engagement with another of the plurality of recesses.
 7. The fuel sender assembly according to claim 1, wherein the first part of the second positioning mechanism defines a first track part and the second part defines a second track part that is slidably movable along the first track part.
 8. The fuel sender assembly according to claim 7, wherein the first track part has T-shaped projection as viewed in cross-section and the second track part includes two opposing recesses dimensioned to receive and mate with the T-shaped projection.
 9. The fuel sender assembly according to claim 7, wherein the first part includes a plurality of recesses and the second part includes a movable projection, the plurality of recess and the projection defining the locking mechanism, such that in the locked state the projection extends into one of the plurality of recesses and in the unlocked state the projection is withdrawn from the plurality of recesses.
 10. The fuel sender assembly according to claim 1, wherein the second part of the second positioning mechanism includes a slider track configured to support the float of the sender unit for linear vertical movement along the slider track.
 11. The fuel sender assembly according to claim 10, wherein the float of the sender unit is movable between a plurality of positions along the slider track and the slider track includes a resistance measuring part that provides an electronic indication of electrical resistance at each of the plurality of positions.
 12. The fuel sender assembly according to claim 11, wherein the sender unit includes a circuit and a multi-position switch such that in a first position the multi-position switch sets the resistance measuring part with a first electrical resistance output range and in a second position sets the resistance measuring part with a second electrical resistance output range different from the first resistance output range.
 13. The fuel sender assembly according to claim 1, wherein the first direction is horizontal and the second direction is vertical.
 14. The fuel sender assembly according to claim 3, wherein the attachment section includes at least one support rod that extends to the housing, the support rod being attached to the housing.
 15. The fuel sender assembly according to claim 14, wherein the support rod including a position adjusting mechanism such that the housing is movable between a first position and a second position, such that in the first position the housing is a first distance away from the attachment section and in the second position the housing is a second distance away from the attachment section, the first distance being greater than the second distance.
 16. The fuel sender assembly according to claim 3, wherein the attachment section includes at least one air flow valve assembly operable between an open orientation allowing air flow therethrough and a closed orientation preventing air flow therethrough. 